Tubular interconnecting support structure

ABSTRACT

A tubular support structure ( 20 ) includes a first section ( 22 ) and a second section ( 24 ) longitudinally interconnected with the first section ( 22 ). A third section ( 66 ) is longitudinally interconnected with the second section ( 24 ), and has an end that abuts an end of the first section ( 22 ) to form a butt joint ( 76 ). A fastener system ( 46 ) couples the first and third sections ( 22, 66 ) with the second section ( 24 ), the fastener system ( 46 ) being retained internal to the first, second, and third sections ( 22, 24, 66 ). Multiple sections can be assembled to form a variable length support ( 20 ), with the resulting multiple butt joints ( 76 ) formed between pairs of sections along support ( 20 ) being longitudinally offset along support ( 20 ) relative to one another.

RELATED INVENTION

The present invention is a continuation in part (CIP) of “Tubular Interconnecting Support Structure,” U.S. patent application Ser. No. 11/266,847, filed 3 Nov. 2005, still pending, which claims priority under 35 U.S.C. §119(e) to “Continuous Beam,” U.S. Provisional Patent Application Ser. No. 60/626,255, filed 8 Nov. 2004, both of which are incorporated by reference herein.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the field of tubular support structures. More specifically, the present invention relates to a tubular support structure system for accommodating varying lengths of rolled up materials.

BACKGROUND OF THE INVENTION

Elongated tubular structures that support materials, such as rolled up fabric, paper, and the like, may be needed of varying lengths to accommodate varying widths of such materials. Stocking multiple independent tubular structures to accommodate varying lengths of materials is impractical and expensive. In addition, at greater lengths, a tubular structure may bow or permanently deform due the weight of the material it is supporting.

Market demand has lead to the development of quilting devices for holding fabric to be quilted and moving a sewing machine relative to the fabric. A typical quilting device includes a frame system for holding the fabric to be quilted, and a platform supporting a sewing machine for moving the sewing machine relative to the fabric. Generally, the frame holds one or more payout rollers, onto which fabric is rolled, and a take-up roller. The take-up roller is typically directed through the throat of the sewing machine so that fabric suspended between the payout rollers and the take-up roller can be passed under the needle bar of the sewing machine for machine stitching. The platform typically includes two carriages, one sitting upon the other. One carriage moves in a longitudinal direction, and the other carriage moves upon the first carriage in a transverse direction. The platform can then be manipulated by the user to impart a stitch pattern onto the fabric.

The pay-out and take-up rollers may be short to support fabric for making small quilts, such as baby quilts or wall hangings, or may be elongated to support fabric for making quilts of greater width to accommodate, for example, king sized beds. Fabric rolled onto these elongated rollers can be heavy, thus causing bowing or deformation of the rollers. In addition, the use of elongated rollers for making small quilts can be quite cumbersome for the user. Moreover, maintaining an inventory of rollers in varying lengths for accommodating a wide variety of fabric widths is costly and unwieldy to store.

SUMMARY OF THE INVENTION

Accordingly, it is an advantage of the present invention that a tubular interconnecting support structure is provided.

It is another advantage of the present invention that a tubular interconnecting support structure is provided that is created from sections for accommodating a wide variety of material widths rolled thereon.

Another advantage of the present invention is that a tubular interconnecting support structure is provided that is resistant to bowing and/or permanent deformation from the weight of the material rolled thereon.

The above and other advantages of the present invention are carried out in one form by a tubular support structure including a first section and a second section longitudinally interconnected with the first section. A fastener couples the second section with the first section, the fastener being retained internal to the first and second sections.

The above and other advantages of the present invention are carried out in another form by a tubular support structure comprising a first section and a second section. The first section includes a first longitudinal edge having a first tongue portion and a second longitudinal edge having a first groove portion. The second section includes a third longitudinal edge having a second tongue portion and a fourth longitudinal edge having a second groove portion. The second tongue portion fits in the first groove portion and the first tongue portion fits in the second groove portion to interconnect the first and second sections. Each of the first and second sections includes inwardly extending ribs. A fastener couples the second section with the first section, the fastener being retained internal to the first and second sections.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:

FIG. 1 shows an exploded end view of a tubular interconnecting support structure in accordance with a preferred embodiment of the present invention;

FIG. 2 shows an end view of the tubular interconnecting support structure of FIG. 1;

FIG. 3 shows a side view of the interconnecting support structure of FIG. 1;

FIG. 4 shows an exploded perspective end view of the tubular interconnecting support structure of FIG. 1;

FIG. 5 shows an exploded end view of a tubular interconnecting support structure in accordance with an alternative embodiment of the present invention;

FIG. 6 shows an end view of the tubular interconnecting support structure of FIG. 5;

FIG. 7 shows an exploded end view of a tubular interconnecting support structure in accordance with another alternative embodiment of the present invention; and

FIG. 8 shows an end view of the tubular interconnecting support structure of FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a tubular interconnecting support structure for supporting material, such as, fabric, quilt batting, paper, and the like rolled thereon. Such a support structure may be effectively utilized on a quilting frame as fabric rollers that allow variable length configurations. However, the tubular interconnecting support structure is not limited to such a use. In addition, it may be utilized as a bar from which items are suspended, as a beam within another structure, and the like.

Referring to FIGS. 1-2, FIG. 1 shows an exploded end view of a tubular interconnecting support structure 20 in accordance with a preferred embodiment of the present invention. FIG. 2 shows an end view of tubular interconnecting support structure 20.

Tubular interconnecting support structure 20 includes a first section 22 and a second section 24 that mate and form longitudinally oriented joints 26. In particular, first section 22 includes a first longitudinal edge 28 having a first tongue portion 30, and a second longitudinal edge 32 having a first groove portion 34. Correspondingly, second section 24 includes a third longitudinal edge 36 having a second tongue portion 38, and a fourth longitudinal edge 40 having a second groove portion 42.

As shown, second tongue portion 38 of second section 24 fits into first groove portion 34 of first section 22. Likewise, first tongue portion 30 of first section 22 fits into second groove portion 42 of second section 24. This interlocking fit along longitudinally oriented joints 26 yields a sturdy joint resistant to separation when subjected to shear forces.

First and second sections 22 and 24 include rib members 44 that extend inwardly into the interior of the tubular support structure 20. Rib members 44 are radially oriented and run the length of first and second sections 22 and 24. Rib members 44 provide structural reinforcement so that tubular support structure 20 is resistant to bowing and/or permanent deformation due to the weight of the material rolled onto or suspended from structure 20.

First and second sections 22 and 24 are held together via a fastener system 46 that includes a fastener 48 and a connecter element 50 having a receiving section, in the form of a threaded opening 52, for retaining a distal end 54 of fastener 48. Fastener 48 and connector element 50 are located internal to first and second sections 22 and 24. More specifically, first section 22 includes an integrally formed first trough 56 that slidably captures a head 58 of fastener 48. Second section 24 includes an integrally formed second trough 60 that slidably captures connector element 50.

In operation, head 58 of fastener 48 is slid into first trough 56, and connector element 50 is slid into second trough 60. Fastener head 58 is accessible via an access opening 62 through first section 22. Distal end 54 of fastener 48 can then be secured to threaded opening 52 by inserting a tool, such as a hex head wrench or screwdriver, into fastener head 54 through access opening 62. As fastener 48 is secured to connector element 50, first and second sections 22 and 24, respectively, are coupled tightly together by the forces imposed on inner surfaces 64 of first and second troughs 56 and 60, respectively, by fastener head 58 and connector element 50, respectively.

First and second sections 22 and 24, exhibit a generally arcuate or curved cross-sectional shape. Consequently, when first and second sections 22 and 24 are coupled together, the resulting cross-sectional shape of tubular support structure is elliptical, and in this example, generally circular in nature. In an exemplary embodiment, first and second sections 22 and 24 are identically shaped and can be manufactured using, for example, an extrusion process. First and second sections 22 and 24 may be formed from aluminum, a rigid plastic material, and so forth, and can be cut into various pre-determined lengths.

Referring now to FIGS. 3-4 in connection with FIGS. 1-2, FIG. 3 shows a perspective view of a portion of interconnecting support structure 20, and FIG. 4 shows an exploded perspective end view of tubular interconnecting support structure 20. As shown in FIG. 3, a variable length tubular support structure is formed utilizing additional sections.

In this example scenario, tubular interconnecting support structure 20 includes first and second sections 22 and 24, respectively. In addition, structure 20 includes a third section 66 and a fourth section 68. Additional sections 70 can be added to structure 20 until a desired length is reached. The discussion below applying to third and fourth sections 66 and 68, respectively, can be applied equivalently to additional sections 70.

Third and fourth sections 66 and 68 are shaped identically to first and second sections 22 and 24, respectively. Therefore, the above-presented discussion need not be repeated. Third section 66 is longitudinally interconnected with second section 24 and has a first end 72 abutting a second end 74 of first section 22 to form one of a number of butt joints 76. A blown-up view of butt joint 76 between first and third sections 22 and 66, respectively, is presented in FIG. 3 for clarity of illustration to portray the interconnection of first and third sections 22 and 66 with second section 24.

Connector element 50 is a connector bar having threaded opening 52, referred to hereinafter as first threaded opening 52, for attachment of fastener 48, referred to hereinafter as first fastener 48. Connector element 50 further includes a second receiving section, in the form of a second threaded opening 78 for attachment of a second fastener 80 of fastener system 46 that functions to couple third section 66 with second section 24.

Assembly of tubular interconnecting support structure 20 to form butt joint 76 entails attaching first fastener 48 to threaded opening 52 of connector element 50, and attaching second fastener 80 to second threaded opening 78 of connector element. Connector element 50 can then be slid to the desired location in second trough 60. Each of first and third sections 22 and 66, respectively, are then mated with second section 24 and adjusted such that access opening 62 of each of first and third sections 22 and 66 align with first and second fasteners 48 and 80, respectively. First and second fasteners 48 and 80 are then tightened into first and second threaded openings 52 and 78 to tightly couple first and third sections 22 and 66 with second section 24. This procedure can be repeated with fourth section 68 and each of sections 70 until a desired length of structure 20 has been attained.

Retention of first and second fasteners 48 and 80 in first trough 56 and retention of connector bar 50 in second trough 60, and the attachment of first and second fasteners 48 and 80 to connector bar 50 yields a strong butt joint 76 that is resistant to bending and/or permanent deformation when subjected to the loads imposed on tubular interconnected support structure 20.

It should be noted that each end of support structure 20, of which only one is shown in FIG. 3 may include a mechanism, such as a post or spindle 82, for attachment to another structure. For example, when tubular interconnecting support structure 20 is used in connection with a quilting table, posts 82 may couple structure 20 to supports attached to the frame of a quilting table. Fastener system 46, such as first fastener 48 and connector 50, may be installed into first and second sections 22 and 24, respectively, proximate spindle 82 to serve as a stop so that spindle 82 is prevented from sliding too far into tubular interconnecting support structure 20.

As further shown in FIG. 3, butt joints 76 can be offset or staggered for additional structural integrity. For example, another of butt joints 76 is formed between a third end 84 of fourth section 68 and a fourth end 86 of second section 24. Butt joint 76 formed between second and fourth sections 24 and 68, respectively, is longitudinally offset or spaced apart from butt joint 76 between first and third sections 22 and 66, respectively.

In a preferred embodiment, connection at butt joints 76 is accomplished utilizing fastener system 46. However, those skilled in the art will recognize that other temporary fastener techniques may alternatively be employed, or the joint connection may be made permanent by welding, gluing and the like. In addition, although the sections of tubular support structure 20 are joined utilizing an internally located fastener system 46, they may alternatively be joined externally.

Tubular support structure 20 is formed by longitudinally connected pairs of sections, each section forming half of the circumference of support structure 20. However, such is not a limitation of the present invention. Rather, tubular support structure 20 may be formed of multiple longitudinally connected sections. By way of example, in an alternative embodiment, a tubular support structure may be formed from four sections, where each section forms one quarter of the circumference of the tubular interconnecting support structure.

Referring to FIGS. 5-6, FIG. 5 shows an exploded end view of a tubular interconnecting support structure 90 in accordance with an alternative embodiment of the present invention, and FIG. 6 shows an end view of tubular interconnecting support structure 90. Tubular support structure 90 includes a first section 92 and a second section 94 that mate to form longitudinally oriented joints 96.

Each of first hand second sections 92 and 94, respectively, includes a first outer surface 98 and a second outer surface 100 oriented approximately perpendicular to first outer surface 98. Consequently, interconnection of first and second sections 92 and 94 yields tubular support structure 90 exhibiting a rectangular cross-sectional shape, and in this example, generally square in nature.

Like tubular support structure 20 (FIG. 1), first section 92 includes a first longitudinal edge 102 having a first tongue portion 104, and a second longitudinal edge 106 having a first groove portion 108. Correspondingly, second section 94 includes a third longitudinal edge 110 having a second tongue portion 112, and a fourth longitudinal edge 114 having a second groove portion 116.

As shown, second tongue portion 112 of second section 94 fits into first groove portion 108 of first section 92. Likewise, first tongue portion 104 of first section 92 fits into second groove portion 116 of second section 94. This interlocking fit along longitudinally oriented joints 96 yields a sturdy joint resistant to separation when subjected to shear forces.

First and second sections 92 and 94 include rib members 118 that extend inwardly into the interior of the tubular support structure 90. Rib members 118 run the length of first and second sections 92 and 94, and provide structural reinforcement so that tubular support structure 90 is resistant to bowing and/or permanent deformation due to the weight of the material rolled onto or suspended from structure 20.

First section 92 further includes a first tab element 120 extending from an interior surface 122 of first section 92. Likewise, second section 92 includes a second tab element 124 extending from an interior surface 126 of second section 94. First and second tab elements 120 and 124 are hook shaped and are oriented in opposing relation with one another. This orientation produces a central channel 128 between first and second tab elements 120 and 124, respectively.

A longitudinally oriented pin 130 is seated in this central channel 128. Pin 130 produces a tensioning force, represented by outwardly directed arrows 132, against first and second tab elements 120 and 124, respectively. Tensioning force 132 serves to hold first and second sections 92 and 94, respectively, together. Pin 130 may extend from an end of structure 90 so that another pair of first and second section 92 and 94, respectively may be coupled thereon to form a variable length tubular interconnecting support structure 90. In such a configuration, one or both of first and second tab elements 120 and 124, respectively, may optionally include a stop so that pin 130 is prevented from sliding too far into central channel 128. Similar to the configuration of FIGS. 1-4, butt joints (not shown) of structure 90 can be staggered for additional structural integrity.

Referring to FIGS. 7-8, FIG. 7 shows an exploded end view of a tubular interconnecting support structure 136 in accordance with another alternative embodiment of the present invention, and FIG. 8 shows an end view of tubular interconnecting support structure 136. Tubular support structure 136 is of a generally circular cross-sectional shape having a first section 138 and second section 140 that also mate to form longitudinally oriented joints 142. Tubular support structure 136 shares many of the features of tubular support structure 20, such as variability of length, internal fasteners, tongue and groove mating longitudinal edges, and the like. Hence, they need not be repeated herein.

Like tubular support structures 20 (FIG. 1) and 90 (FIG. 5) discussed above, first and second sections 138 and 140 also include rib members 144 that extend inwardly into the interior of structure 136 for strength. However, unlike rib members 44 (FIG. 1) of tubular support structure 20, rib members 144 deviate away from a radial direction of tubular support structure 136. This deviation of rib members 144 produces a generally rectangular central cavity 146. Rectangular central cavity 146 can accommodate a pin, such as spindle 82 (FIG. 3) having a rectangular cross section.

The tubular interconnecting support structures shown in FIGS. 1-8 may be implemented on a quilting frame as fabric rollers that allow variable length configurations. The variable length rollers allow for accommodation of a narrower quilt (for example, less than forty-seven inches in width) through a much wider “king sized” quilt (for example, approximately one hundred and five inches in width). Such beam-like fabric rollers and the internally located ribs are structurally rigid, durable, and readily assembled, while retaining the ability of break down into shorter parts for convenient storage and shipping.

In summary, the present invention teaches of a tubular interconnecting support structure that is created from sections for accommodating a wide variety of material widths rolled thereon. The tubular interconnecting support structure includes internally extending ribs and longitudinally offset butt joints that are resistant to bowing and/or permanent deformation.

Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. 

1. A tubular support structure comprising: a first section; a second section longitudinally interconnected with said first section; and a fastener coupling said second section with said first section, said fastener being retained internal to said first and second sections.
 2. A tubular support structure as claimed in claim 1 wherein each of said first and second sections includes inwardly extending ribs.
 3. A tubular support structure as claimed in claim 2 wherein said inwardly extending ribs are radially oriented.
 4. A tubular support structure as claimed in claim 2 wherein said inwardly extending ribs are directed away from a radial direction of said tubular support structure to form a generally rectangular central cavity.
 5. A tubular support structure as claimed in claim 1 wherein each of said first and second sections exhibits an arcuate cross-sectional shape such that interconnection of said first and second sections yields said tubular support structure exhibiting an elliptical cross-sectional shape.
 6. A tubular support structure as claimed in claim 1 wherein each of said first and second sections comprises: a first outer surface; and a second outer surface oriented approximately perpendicular to said first outer surface such that interconnection of said first and second sections yields said tubular support structure exhibiting a rectangular cross-sectional shape.
 7. A tubular support structure as claimed in claim 1 wherein: said first section comprises an integrally formed trough slidably capturing a head of said fastener; and said second section comprises means for retaining a distal end of said fastener.
 8. A tubular support structure as claimed in claim 7 wherein: said retaining means of second section comprises a second integrally formed trough; and said tubular support structure further comprises a connector element slidably captured in said second trough, said connector element having a receiving section for retaining said distal end of said fastener.
 9. A tubular support structure as claimed in claim 1 wherein: said first section comprises a first tab element extending from a first interior surface of said first section; said second section comprises a second tab element extending from a second interior surface of said second section, said second tab element being oriented in opposing relation with said first tab element to form a central channel between said first and second tab elements; and said fastener comprises a longitudinally oriented pin seated in said central channel, said pin producing a tensioning force against said first and second tab elements to hold said first and second sections together.
 10. A tubular support structure as claimed in claim 1 wherein: said first section comprises a first longitudinal edge having a first tongue portion and a second longitudinal edge having a first groove portion; and said second section comprises a third longitudinal edge having a second tongue portion and a fourth longitudinal edge having a second groove portion, said second tongue portion fitting in said first groove portion and said first tongue portion fitting in said second groove portion to interconnect said first and second sections.
 11. A tubular support structure as claimed in claim 1 further comprising a third section longitudinally interconnected with said second section, and having a first end abutting a second end of said first section to form a butt joint.
 12. A tubular support structure as claimed in claim 11 wherein said fastener is a first fastener, and said structure further comprises: a second fastener for coupling said third section with said second section; and a connector bar slidably captured in an integrally formed trough of said second section, said connecter bar having a first receiving section for retaining a first distal end of said first fastener and a second receiving section for retaining a second distal end of said second fastener.
 13. A tubular support structure as claimed in claim 11 wherein said butt joint is a first butt joint, and said structure further comprises a fourth section having a third end abutting a fourth end of said second section to form a second butt joint longitudinally offset along said tubular support structure from said first butt joint.
 14. A tubular support structure comprising: a first section, said first section including a first longitudinal edge having a first tongue portion and a second longitudinal edge having a first groove portion; a second section, said second section including a third longitudinal edge having a second tongue portion and a fourth longitudinal edge having a second groove portion, said second tongue portion fitting in said first groove portion and said first tongue portion fitting in said second groove portion to interconnect said first and second sections, and each of said first and second sections including inwardly extending ribs; and a fastener coupling said second section with said first section, said fastener being retained internal to said first and second sections.
 15. A tubular support structure as claimed in claim 14 wherein: said first section comprises an integrally formed trough slidably capturing a head of said fastener; and said second section comprises means for retaining a distal end of said fastener.
 16. A tubular support structure as claimed in claim 15 wherein: said retaining means of said second section further comprises a second integrally formed trough; and said tubular support structure further comprises a connector element slidably captured in said second trough, said connector element having a receiving-section for retaining said distal end of said fastener.
 17. A tubular support structure comprising: a first section; a second section longitudinally interconnected with said first section; a third section longitudinally interconnected with said second section, and having a first end abutting a second end of said first section to form a butt joint; and a fastener system coupling said second section with said first and third sections, said fastener system being retained internal to said first, second, and third sections.
 18. A tubular support structure as claimed in claim 17 wherein: said fastener system includes a first fastener and a second fastener; said first section comprises a first integrally formed trough slidably capturing a first head of said first fastener; said third section comprises a second integrally formed trough slidably capturing a second head of said second fastener; and said second section comprises means for retaining a distal end of each of said first and second fasteners.
 19. A tubular support structure as claimed in claim 18 wherein: said retaining means of said second section includes a third integrally formed trough; and said fastener system further comprises a connector bar slidably captured in said third trough, said connecter bar having a first receiving section for retaining said distal end of said first fastener and a second receiving section for retaining said distal end of said second fastener.
 20. A tubular support structure as claimed in claim 17 wherein said butt joint is a first butt joint, and said structure further comprises a fourth section having a third end abutting a fourth end of said second section to form a second butt joint longitudinally offset along said tubular support structure from said first butt joint. 